In-Process Inspection System and Automated Manufacturing System for Fabricating Optimized Reinforced Thermoplastic Composites Structures
Abstract
The primary goal of this research is to develop manufacturing protocols for automated thermoplastic primary structures using inprocess monitoring to improve part quality. Secondary goals include in-depth investigation of automated RTP joining protocols and integration of lightning protection layers into RTP structures. High-performance thermoplastic resin systems can be reinforced with high strength structural fibers along with a coupling agent in order to expand the use of thermoplastics into primary structural applications. In addition to impact, chemical, and flame resistance, thermoplastic material systems offer several attractive benefits for naval applications, because of their resistance to aggressive environments such as high-humidity, high temperature, and salt water exposure as well as less stringent cleanroom requirements and no shelf life. Because of these advantages, reinforced thermoplastics (RTP) are now considered for key structural applications and integration into automated manufacturing processes such as automated fiber placement (AFP) and automated tape laying (ATL). One of the challenges with the use of RTP for structural application is that they are extremely sensitive to processing variables. Due to numerous key processing parameters that contribute to final material characteristics, certification of RTP structures is challenging. Therefore, building-block approach that typically followed by the manufacturers for certification requires significant amount of additional analyses and testing conducted at higher levels than typical coupon-level allowables. Recent advances in laser heating technologies and automated manufacturing technologies have enabled the use of RTP in AFP/ATL manufacturing processes. In order to consolidate FTP and cure the resin system, a high-powered heater (ex., laser diodes or hot gas) with a direct feedback loop is required for actively providing material. This eliminates the secondary processes such as vacuum bagging and autoclave/oven curing, which significantly reduce the manufacturing cost and increase the production rates. In-situ consolidation coupled with automation provides tremendous advantages for improving the production rates, consistency, and part quality. Currently, AFP/ATL processes are interrupted after each layer so that the layup can be manually inspected for defects. This manual inspection process that can consume 20% or more of the production time diminishes the values of automation to improve production rate. Therefore, there is a great demand for developing in-process inspection techniques for AFP/ATL.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Apr 24, 2019
- Source ID
- N000141912166
Entities
People
- Waruna Seneviratne
Organizations
- Office of Naval Research
- United States Navy
- Wichita State University